Gradual oxidation apparatus

Abstract

An oxidation apparatus configured to receive a gas stream, the oxidation apparatus having: an apparatus inlet port; a heat exchanger in fluid communication with the apparatus inlet port, the heat exchanger having: a cold gas channel in fluid communication with the apparatus inlet port; and a hot gas channel in thermal communication with the cold gas channel; a reactor inlet port in fluid communication with the cold gas channel; a reactor body in fluid communication with the reactor inlet port; a reactor outlet port in fluid communication with the reactor body and the hot gas channel; and an apparatus outlet port in fluid communication with the hot gas channel. The reactor body is configured to continuously oxidize fuel gas within the gas stream, such that gas travelling through the hot gas channel heats gas travelling through the cold gas channel, preheating the gas stream prior to entering the reactor body.

What is claimed is: 
     
         1 . An oxidation apparatus configured to receive a gas stream having a fuel gas mixed with a carrier gas, the carrier gas comprising oxygen, wherein the concentration of the fuel gas in the gas stream is below a combustible range, the oxidation apparatus comprising:
 an apparatus inlet port configured to receive the gas stream;   a heat exchanger in fluid communication with the apparatus inlet port, the heat exchanger comprising:
 a cold gas channel in fluid communication with the apparatus inlet port; and 
 a hot gas channel in thermal communication with the cold gas channel; 
   a reactor inlet port in fluid communication with the cold gas channel;   a variable area reactor body in fluid communication with the reactor inlet port, the variable area reactor body comprising:
 a first expanding flow area portion in fluid communication with the reactor inlet port; 
 a reactor channel with a large flow area in fluid communication with the first expanding flow area portion; and 
 a second decreasing flow area portion in fluid communication with the reactor channel; 
   a reactor outlet port in fluid communication with the second decreasing flow area portion;   a soaker channel in fluid communication with the reactor outlet port and the hot gas channel; and   an apparatus outlet port in fluid communication with the hot gas channel, wherein the apparatus outlet port is configured to emit the gas stream from the oxidation apparatus;   
       wherein the oxidation apparatus is configured to provide the gas stream with heating to achieve gradual oxidation of the fuel gas, whereby the gradual oxidation of the fuel gas raises the temperature of the gas stream, thus increasing the oxidation rate of the fuel gas and further increasing the temperature of the gas stream; such that heat is transferred from higher temperature gas travelling through the hot gas channel to lower temperature gas travelling through the cold gas channel, raising the temperature of the lower temperature gas travelling through the cold gas channel to initiate and maintain gradual oxidation of the fuel gas, to facilitate substantial oxidation of the fuel gas of the gas stream within the oxidation apparatus. 
     
     
         2 . The oxidation apparatus of  claim 1 , wherein the variable area reactor body is made from a ceramic material. 
     
     
         3 . The oxidation apparatus of  claim 1 , wherein the variable area reactor body is configured to be preheated prior to receiving the continuous gas stream. 
     
     
         4 . An oxidation apparatus configured to receive a continuous gas stream having a fuel gas mixed with a carrier gas, the carrier gas comprising oxygen, wherein the concentration of the fuel gas in the continuous gas stream is below a combustible range, the oxidation apparatus comprising:
 an apparatus inlet port configured to receive the continuous gas stream;   a heat exchanger in fluid communication with the apparatus inlet port, the heat exchanger comprising:
 a cold gas channel in fluid communication with the apparatus inlet port; and 
 a hot gas channel in thermal communication with the cold gas channel; 
   a reactor inlet port in fluid communication with the cold gas channel;   a reactor body in fluid communication with the reactor inlet port, wherein the reactor body has a first, smaller flow area and a second, larger flow area;   a reactor outlet port in fluid communication with the reactor body and the hot gas channel of the heat exchanger; and   an apparatus outlet port in fluid communication with the hot gas channel, wherein the apparatus outlet port is configured to emit the continuous gas stream from the oxidation apparatus;   
       wherein the oxidation apparatus is configured to provide the continuous gas stream with heating to achieve gradual oxidation of the fuel gas, whereby the gradual oxidation of the fuel gas raises the temperature of the continuous gas stream, thus increasing the oxidation rate of the fuel gas and further increasing the temperature of the continuous gas stream; such that heat is transferred from higher temperature gas travelling through the hot gas channel to lower temperature gas travelling through the cold gas channel, raising the temperature of the lower temperature gas travelling through the cold gas channel to initiate and maintain gradual oxidation of the fuel gas, to facilitate substantial oxidation of the fuel gas of the continuous gas stream within the oxidation apparatus. 
     
     
         5 . The oxidation apparatus of  claim 4 , wherein the fuel gas comprises at least one material selected from a group consisting of: methane; hydrocarbon compounds; hydrogen; carbon monoxide; and ammonia. 
     
     
         6 . The oxidation apparatus of  claim 4 , wherein the fuel gas is generated as a byproduct of a separate process. 
     
     
         7 . The oxidation apparatus of  claim 6 , wherein the gradual oxidation of the fuel gas is controlled and maintained by providing additional fuel gas to the oxidation apparatus. 
     
     
         8 . The oxidation apparatus of  claim 4 , wherein the reactor body is configured to be preheated prior to receiving the continuous gas stream. 
     
     
         9 . The oxidation apparatus of  claim 4 , wherein the reactor body is made from metal. 
     
     
         10 . The oxidation apparatus of  claim 4 , wherein the reactor body is made from a ceramic material. 
     
     
         11 . The oxidation apparatus of  claim 4 , wherein the reactor body is made from composite materials. 
     
     
         12 . The oxidation apparatus of  claim 4 , wherein the reactor body is a coiled reactor body. 
     
     
         13 . The oxidation apparatus of  claim 4 , wherein the reactor body is a forked reactor body. 
     
     
         14 . The oxidation apparatus of  claim 4 , wherein the reactor body is a serpentine reactor body. 
     
     
         15 . The oxidation apparatus of  claim 4 , wherein the carrier gas is air. 
     
     
         16 . The oxidation apparatus of  claim 4 , further comprising a soaker channel, wherein the soaker channel is disposed between and in fluid communication with the reactor outlet port and the hot gas channel. 
     
     
         17 . An oxidation apparatus configured to receive an input gas stream and emit an output gas stream, the input gas stream having a fuel gas mixed with a carrier gas, the carrier gas comprising oxygen, wherein the concentration of fuel gas within the input gas stream is below a combustible range, the oxidation apparatus comprising:
 a heat exchanger configured to receive the input gas stream and transfer heat from the output gas stream to the input gas stream to raise the temperature of the input gas stream;   a reactor body in fluid communication with the heat exchanger, wherein the reactor body is configured receive the input gas stream from the heat exchanger, substantially oxidize the fuel gas within the input gas stream to form the output gas stream and emit the output gas stream to the heat exchanger; and   a soaker channel, wherein the soaker channel is disposed between and in fluid communication with the reactor body and the heat exchanger;   
       wherein the oxidation apparatus is configured to provide the input gas stream with heating to achieve gradual oxidation of the fuel gas, whereby the gradual oxidation of the fuel gas raises the temperature of the input gas stream, thus increasing the oxidation rate and increasing the temperature of the input gas stream within the oxidation apparatus to initiate and maintain gradual oxidation of the fuel gas, to facilitate substantial oxidation of the fuel gas within the oxidation apparatus. 
     
     
         18 . The oxidation apparatus of  claim 17 , wherein the reactor body is a serpentine reactor body.